1. DU THE GATEWAY COALITION TELE-MANUFACTURING IN CONCURRENT ENGINEERING A COURSE MODULE IN CONCURRENT ENGINEERING FOR GATEWAY EEC PROJECT Dr. Jack Zhou Department of Mechanical Engineering and Mechanics Drexel University, Philadelphia, PA

2. DU THE GATEWAY COALITION Tele-Manufacturing In Concurrent Engineering-A Course Module Course Description: This course will introduce a new concept and methodology-Concurrent Engineering (CE) into design and manufacturing curriculum. A latest technology, Telemanufacturing in CE, which integrates 3-D solid modeling, CAD/CAM, Rapid prototyping, Telecommunication and networking into an intelligent manufacturing process system, will be taught systematically. A comprehensive application project (example) ‘Design and Manufacturing of a Race Car Spindle’ will be illustrated to further understand Telemanufacturing in CE. Course Length: This is a two hour lecture, three hour reading and two hour homework course module.

3. DU THE GATEWAY COALITION Tele-Manufacturing In Concurrent Engineering-A Course Module Reading Materials: ¬Jack Zhou etc., “Concurrent Engineering Concept Applied in Concurrent Education and Research”;Proceedings of 3rd International Conference in Concurrent Engineering Research and Applications, August, 1996, Toronto, Canada. ­Tien-C. Chang etc., Computer-Aided Manufacturing, chapters 6 and 8, Prentice Hall, 92 ®Michael Bailey, “Tele-manufacturing: Rapid Prototyping on the Internet,” IEEE Journal of Computer Graphics and Applications, November 1995, pp. 20-26. Homework: Answer the following: 1. How important do you think Concurrent Engineering and Telemanufacturing are in industry? in university? What are the benefits/drawbacks of Concurrent Engineering and Telemanufacturing. 2. What is the advantage of rapid prototyping compares to conventional methods, can rapid prototyping provide avenues to rapid fabrication/manufacturing? 3.What are the major tools available to implement Concurrent Engineering/Telemanufacturing. What is the availability of these tools at Drexel U. ?

4. DU THE GATEWAY COALITION INTRODUCTION What is Concurrent Engineering? What is Concurrent Education? What is Tele-Manufacturing in Concurrent Engineering?

5. DU THE GATEWAY COALITION What is...?

6. DU THE GATEWAY COALITION CONCURRENT ENGINEERING Definition: Simultaneous or parallel consideration of all facets of the product development process (including design, analysis, manufacturing, testing, quality control and marketing) for the purpose of reducing the time to market, cutting down cost, and improving quality.

7. DU THE GATEWAY COALITION SEQUENTIAL AND PARALLEL ENGINEERING

8. DU THE GATEWAY COALITION BENEFITS FROM CONCURRENT ENGINEERING Surveys shows that Concurrent Engineering can reduce the time to market 55%, return on assets 70% higher, and improve overall quality 350% higher

9. DU THE GATEWAY COALITION CONCURRENT EDUCATION Definition: Concurrently introducing latest science and technology into the new curriculum development of our high education system, breaking the barriers of traditional sequential (i.e.. step by step) and isolated curricula, but integrating multi-stages of curricula and interdisciplinary teachings into classroom.

10. DU THE GATEWAY COALITION

11. DU THE GATEWAY COALITION BEST PRACTICE IN CE To better prepare our engineers and to enhance global competitiveness of U.S. industry, the industry’s top 20 “Best Practices” skills should be taught at U.S. universities. Concurrent Engineering integrates the most technologies and skills of the top 20 Best Practice and is an ideal course to train our new generation of engineers.

12. DU THE GATEWAY COALITION TELE-MANUFACTURING IN CONCURRENT ENGINEERING Today’s manufacturing is not only parallel processes, but also a global activity. Taking the advantages of computer networking and telecommunication, a global range tele- manufacturing is possible. Boeing 777 is a good example of CE and Tele- manufacturing. More than 10,000 people and 200 design groups were involved in the creation of the new plane, which is assembled with four million parts provided from all over the world,

13. DU THE GATEWAY COALITION A Typical Example of Concurrent Engineering Application for Boeing 777 A short Movie “21st Century Jet”

14. DU THE GATEWAY COALITION Where To Go….?

15. DU THE GATEWAY COALITION ADVANCED TECHNOLOGIES, SKILLS & TOOLS IN TM AND CE 3-D Solid Modeling Based CAD/CAM/CAE Integrated Manufacturing Systems Stereolithography RP Machine and CNC Machine Computer System Networking

16. DU THE GATEWAY COALITION A TYPICAL CAD/CAM/CAE SOFTWARE FOR CE AND TELE-MANUFACTURING

17. DU THE GATEWAY COALITION INTEGRATED MANUFACTURING SYSTEM FOR CE & TM APPLICATIONS

18. DU THE GATEWAY COALITION A Stereolithography Rapid Prototyping Machine

19. DU THE GATEWAY COALITION Principle of SLA Machine

20. DU THE GATEWAY COALITION How to Create an STL File and File Compression HOW TO CREATE AN STL FILE 1. Create solid model in Master Modeler; 2. Change to Rapid Prototype task; 3. Pick Create Prototype command icon; 4. Pick the part you want to prototype (a Create Prototype form will show up); 5. Select an appropriate Prototype Device; 6. Select Part Positioning to Center; 7. Name Output File and path (If no path is specified, it will be in your current working directory); 8. Type in appropriate value for Absolute Facet Deviation; 9. Pick Show Facets button to see the facets under current setting; 10. Change settings if there is any error message in the last step; 11. Pick OK or Apply button, the stl file with an extension “.stl” will be created. FILE COMPRESSION To compress a file, at UNIX prompt, type compress filename(s), or compress -v filename(s), which will display the percentage of reduction for each compressed file. To decompress a file, type uncompress filename(s).

21. DU THE GATEWAY COALITION Desk Top CNC Machining

22. DU THE GATEWAY COALITION Principle of CNC Machining

23. DU THE GATEWAY COALITION

24. DU THE GATEWAY COALITION Drexel University SUN OR HP WORKSTATION I-DEAS PRO/ENGINEER MASTERCAM AUTOCAD SANDERS 3-D DESK MODELER PRO ENGINEER 3D SYSTEMS SLA-250 RAPID PROTOTYPING MASTERCAMCINCINATTI CNC MACHINING CENTER 3D SYSTEMS SLA-250 RAPID PROTOTYPING FADAL 5-AXIS MACHINING CENTER AT&T Bell Laboratories (New Jersey) State University of NY at Farmingdale New Jersey Institute of Technology TeleManufacturing Integrated Remote Manufacturing TelePrototyping Intergrated Remote Manufacturing

25. DU THE GATEWAY COALITION AN EXAMPLE OF TELE- MANUFACTURING IN CE A Race Car Spindle Design, Analysis, Tele-Rapid Prototyping, and Tele-CNC Machining

26. DU THE GATEWAY COALITION Race Car Competition

27. DU THE GATEWAY COALITION Dragon Race Car Movie

28. DU THE GATEWAY COALITION Our CE Wheel Used in Concurrent Education and Race Car Project

29. DU THE GATEWAY COALITION Rear Wheel Spindle Assembly of FSAE Race Car

30. DU THE GATEWAY COALITION Boundary Conditions and Applied Force in FEA

31. DU THE GATEWAY COALITION FEA Results-Stress and Deformation

32. DU THE GATEWAY COALITION Manufacturing Simulation on I-Deas

33. DU THE GATEWAY COALITION Tele-Manufacturing Procedure The STL file was transferred to the AT&T Bell Lab through internet using File Transfer Protocol (FTP), and by using their rapid prototyping machine a spindle prototype was made. After trials and errors, the final G-code was FTPed to SUNY Farmingdale in New York, and then a aluminum spindle was manufactured using their CNC machining center in 1.5 hrs.

34. DU THE GATEWAY COALITION CNC Tele-Manufacturing Between Drexel and SUNY Farmingdale CNC Machining the Spindle

35. DU THE GATEWAY COALITION CNC Tele-Manufacturing Between Drexel and SUNY Farmingdale Automatic Tool Change

36. DU THE GATEWAY COALITION CONCLUSION Concurrent Engineering as a new methodology and also a new technology has been applied in our teaching and research. Concurrent Education as a new concept has been introduced to our curriculum reformation. As an example, a research project entitled “Design and Manufacturing of a Rear Wheel Spindle and its Assembly for the FSAE Race Car” was conducted by using CE and concurrent education, which resulted in saving time (five weeks student’s school time was used), higher quality (a safety factor ten was obtained from FEA), reducing the cost (the cost reduced from $120.31 to $50.31 per part), and the most importantly trained a new generation of CE force.